Completion system having a sand control assembly, an inductive coupler, and a sensor proximate to the sand control assembly

ABSTRACT

A completion system for use in a well includes a first completion section and a second section. The first completion section has a sand control assembly to prevent passage of particulates, a first inductive coupler portion, and a sensor positioned proximate to the sand control assembly that is electrically coupled to the first inductive coupler portion. The second section is deployable after installation of the first completion section. It includes a second inductive coupler portion to communicate with the first inductive coupler portion, to enable communication between the first completion section&#39;s sensor and another component coupled to the second section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This claims the benefit under 35 U.S.C. §119(e) of the followingprovisional patent applications: U.S. Ser. No. 60/787,592, entitled“Method for Placing Sensor Arrays in the Sand Face Completion,” filedMar. 30, 2006; U.S. Ser. No. 60/745,469, entitled “Method for PlacingFlow Control in a Temperature Sensor Array Completion,” filed Apr. 24,2006; U.S. Ser. No. 60/747,986, entitled “A Method for ProvidingMeasurement System During Sand Control Operation and Then Converting Itto Permanent Measurement System,” filed May 23, 2006; U.S. Ser. No.60/805,691, entitled “Sand Face Measurement System and Re-CloseableFormation Isolation Valve in ESP Completion,” filed Jun. 23, 2006; U.S.Ser. No. 60/865,084, entitled “Welded, Purged and Pressure TestedPermanent Downhole Cable and Sensor Array,” filed Nov. 9, 2006; U.S.Ser. No. 60/866,622, entitled “Method for Placing Sensor Arrays in theSand Face Completion,” filed Nov. 21, 2006; U.S. Ser. No. 60/867,276,entitled “Method for Smart Well,” filed Nov. 27, 2006; U.S. Ser. No.60/890,630, entitled “Method and Apparatus to Derive Flow PropertiesWithin a Wellbore,” filed Feb. 20, 2007, and U.S. Ser. No. 12/767,290,entitled “Completion System Having A Sand Control Assembly, An InductiveCoupler, And Sensor Proximate To The Sand Control Assembly” filed Apr.26, 2010. Each of the above applications is hereby incorporated byreference.

TECHNICAL FIELD

The invention relates generally to a completion system having acompletion section that has a sand control assembly to prevent passageof particulate material, an inductive coupler, and a sensor positionedproximate to the sand control assembly and electrically connected to theinductive coupler portion.

BACKGROUND

A completion system is installed in a well to produce hydrocarbons (orother types of fluids) from reservoir(s) adjacent the well, or to injectfluids into the well. Sensors are typically installed in completionsystems to measure various parameters, including temperature, pressure,and other well parameters.

However, deployment of sensors is associated with various challenges,particularly in wells where sand control is desirable.

SUMMARY

In general, a completion system for use in a well includes a firstcompletion section having a sand control assembly to prevent passage ofparticulate material, a first inductive coupler portion, and a sensorpositioned proximate to the sand control assembly and electricallycoupled to the first induction coupler portion. A second section isdeployable after installation of the first completion section, where thesecond section includes a second inductive coupler portion tocommunicate with the first inductive coupler portion to enablecommunication between the sensor and another component coupled to thesecond section.

Other or alternative features will become apparent from the followingdescription, from the drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a two-stage completion system having an inductivelycoupled wet connect mechanism for deployment in a well, in accordancewith an embodiment.

FIG. 1B provides a slightly different view of the completion system ofFIG. 1A.

FIG. 1C is a schematic diagram of the electrical chain in the completionsystem of FIG. 1A.

FIGS. 1D-1E illustrate other embodiments of a two-stage completionssystem.

FIG. 2 illustrates a lower completion section of the two-stagecompletion system of FIG. 1A, according to an embodiment.

FIG. 3 illustrates an upper completion section of the two-stagecompletion system of FIG. 1A, according to an embodiment.

FIGS. 4-6 illustrate different embodiments of two-stage completionsystems having inductively coupled wet connect mechanisms.

FIGS. 7, 8A, and 12 illustrate different embodiments of two-stagecompletion systems that do not use inductive couplers but which usestingers to deploy sensors.

FIG. 8B illustrates a variant of the FIG. 8A embodiment that includes aninductive coupler.

FIG. 9 is a cross-sectional view of a portion of a stinger and sensorcable in the completion system of FIG. 8A, according to an embodiment.

FIGS. 10 and 11 depict a completion system in which sensors and aninductive coupler portion are arranged outside a casing, according toother embodiments.

FIGS. 13 and 14 illustrate different embodiments of portions of sensorcables usable in the various completion systems.

FIG. 15 illustrates a spool on which a sensor cable is wound, accordingto an embodiment.

FIGS. 16-18 illustrate other types of sensor cables, according tofurther embodiments.

FIG. 19 is a longitudinal cross-sectional view of a completion systemthat includes a shunt tube to which a sensor cable is attached.

FIG. 20 is a cross-sectional view of the shunt tube and sensor cable ofFIG. 19.

FIG. 21 illustrates a completion system for use in a multilateral well,according to another embodiment.

FIG. 22 illustrates a two-stage completion system that is a variant ofthe completion system of FIG. 1A, according to a further embodiment.

FIGS. 23-25 and 27-28 illustrate other embodiments of completion systemsin which inductive couplers are used.

FIG. 26 illustrates another embodiment of a completion system in whichan inductive coupler is not used.

FIG. 29 illustrates an arrangement including a lower completion sectionand an intervention tool capable of communicating with the lowercompletion section using an inductive coupler, according to anotherembodiment.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to providean understanding of the present invention. However, it will beunderstood by those skilled in the art that the present invention may bepracticed without these details and that numerous variations ormodifications from the described embodiments are possible.

As used here, the terms “above” and “below”; “up” and “down”; “upper”and “lower”; “upwardly” and “downwardly”; and other like termsindicating relative positions above or below a given point or elementare used in this description to more clearly describe some embodimentsof the invention. However, when applied to equipment and methods for usein wells that are deviated or horizontal, such terms may refer to a leftto right, right to left, or diagonal relationship as appropriate.

In accordance with some embodiments, a completion system is provided forinstallation in a well, where the completion system allows for real-timemonitoring of downhole parameters, such as temperature, pressure, flowrate, fluid density, reservoir resistivity, oil/gas/water ratio,viscosity, carbon/oxygen ratio, acoustic parameters, chemical sensing(such as for scale, wax, asphaltenes, deposition, pH sensing, salinitysensing), and so forth. The well can be an offshore well or a land-basedwell. The completion system includes a sensor assembly (such as in theform of a sensor array of multiple sensors) that can be placed atmultiple locations across a sand face of a well in some embodiments. A“sand face” refers to a region of the well that is not lined with acasing or liner. In other embodiments, the sensor assembly can be placedin a lined or cased section of the well. “Real-time monitoring” refersto the ability to observe the downhole parameters during some operationperformed in the well, such as during production or injection of fluidsor during an intervention operation. The sensors of the sensor assemblyare placed at discrete locations at various points of interest. Also,the sensor assembly can be placed either outside or inside a sandcontrol assembly, which can include a sand screen, a slotted orperforated liner, or a slotted or perforated pipe.

The sensors can be placed proximate to a sand control assembly. A sensoris “proximate to” a sand control assembly if it is in a zone in whichthe sand control assembly is performing control of particulate material.

In some embodiments, a completion system having at least two stages (anupper completion section and a lower completion section) is used. Thelower completion section is run into the well in a first trip, where thelower completion section includes the sensor assembly. An uppercompletion section is then run in a second trip, where the uppercompletion section is able to be inductively coupled to the firstcompletion section to enable communication and power between the sensorassembly and another component that is located uphole of the sensorassembly. The inductive coupling between the upper and lower completionsections is referred to as an inductively coupled wet connect mechanismbetween the sections. “Wet connect” refers to electrical couplingbetween different stages (run into the well at different times) of acompletion system in the presence of well fluids. The inductivelycoupled wet connect mechanism between the upper and lower completionsections enables both power and signaling to be established between thesensor assembly and uphole components, such as a component locatedelsewhere in the wellbore at the earth surface.

The term two-stage completion should also be understood to include thosecompletions where additional completion components are run in after thefirst upper completion, such as commonly used in some cased-holefrac-pack applications. In such wells, inductive coupling may be usedbetween the lowest completion component and the completion componentabove, or may be used at other interfaces between completion components.A plurality of inductive couplers may also be used in the case thatthere are multiple interfaces between completion components.

Induction is used to indicate transference of a time-changingelectromagnetic signal or power that does not rely upon a closedelectrical circuit, but instead includes a component that is wireless.For example, if a time-changing current is passed through a coil, then aconsequence of the time variation is that an electromagnetic field willbe generated in the medium surrounding the coil. If a second coil isplaced into that electromagnetic field, then a voltage will be generatedon that second coil, which we refer to as the induced voltage. Theefficiency of this inductive coupling increases as the coils are placedcloser, but this is not a necessary constraint. For example, iftime-changing current is passed through a coil is wrapped around ametallic mandrel, then a voltage will be induced on a coil wrappedaround that same mandrel at some distance displaced from the first coil.In this way, a single transmitter can be used to power or communicatewith multiple sensors along the wellbore. Given enough power, thetransmission distance can be very large. For example, solenoidal coilson the surface of the earth can be used to inductively communicate withsubterranean coils deep within a wellbore. Also note that the coils donot have to be wrapped as solenoids. Another example of inductivecoupling occurs when a coil is wrapped as a toroid around a metalmandrel, and a voltage is induced on a second toroid some distanceremoved from the first.

In alternative embodiments, the sensor assembly can be provided with theupper completion section rather than with the lower completion section.In yet other embodiments, a single-stage completion system can be used.

Although reference is made to upper completion sections that are able toprovide power to lower completion sections through inductive couplers,it is noted that lower completion sections can obtain power from othersources, such as batteries, or power supplies that harvest power fromvibrations (e.g., vibrations in the completion system). Examples of suchsystems have been described in U.S. Publication No. 2006/0086498. Powersupplies that harvest power from vibrations can include a powergenerator that converts vibrations to power that is then stored in acharge storage device, such as a battery. In the case that the lowercompletion obtains power from other sources, the inductive coupling willstill be used to facilitate communication across the completioncomponents.

Reference is made to FIGS. 1A, 2, and 3 in the ensuing discussion of atwo-stage completion system according to an embodiment. FIG. 1A showsthe two-stage completion system with an upper completion section 100(FIG. 3) engaged with a lower completion section 102 (FIG. 2).

The two-stage completion system is a sand face completion system that isdesigned to be installed in a well that has a region 104 that isun-lined or un-cased (“open hole region”). As shown in FIG. 1A, the openhole region 104 is below a lined or cased region that has a liner or acasing 106. In the open hole region, a portion of the lower completionsection 102 is provided proximate to a sand face 108.

To prevent passage of particulate material, such as sand, a sand screen110 is provided in the lower completion section 102. Alternatively,other types of sand control assemblies can be used, including slotted orperforated pipes or slotted or perforated liners. A sand controlassembly is designed to filter particulates, such as sand, to preventsuch particulates from flowing from a surrounding reservoir into a well.

In accordance with some embodiments, the lower completion section 102has a sensor assembly 112 that has multiple sensors 114 positioned atvarious discrete locations across the sand face 108. In someembodiments, the sensor assembly 112 is in the form of a sensor cable(also referred to as a “sensor bridle”). The sensor cable 112 isbasically a continuous control line having portions in which sensors 114are provided. The sensor cable 112 is “continuous” in the sense that thesensor cable provides a continuous seal against fluids, such as wellborefluids, along its length. Note that in some embodiments, the continuoussensor cable can actually have discrete housing sections that aresealably attached together. In other embodiments, the sensor cable canbe implemented with an integrated, continuous housing without breaks.

In the lower completion section 102, the sensor cable 112 is alsoconnected to a controller cartridge 116 that is able to communicate withthe sensors 114. The controller cartridge 116 is able to receivecommands from another location (such as at the earth surface or fromanother location in the well, e.g., from control station 146 in theupper completion section 100). These commands can instruct thecontroller cartridge 116 to cause the sensors 114 to take measurementsor send measured data. Also, the controller cartridge 116 is able tostore and communicate measurement data from the sensors 114. Thus, atperiodic intervals, or in response to commands, the controller cartridge116 is able to communicate the measurement data to another component(e.g., control station 146) that is located elsewhere in the wellbore orat the earth surface. Generally, the controller cartridge 116 includes aprocessor and storage. The communication between sensors 114 and controlcartridge 116 can be bi-directional or can use a master-slavearrangement.

The controller cartridge 116 is electrically connected to a firstinductive coupler portion 118 (e.g., a female inductive coupler portion)that is part of the lower completion section 102. As discussed furtherbelow, the first inductive coupler portion 118 allows the lowercompletion section 102 to electrically communicate with the uppercompletion section 100 such that commands can be issued to thecontroller cartridge 116 and the controller cartridge 116 is able tocommunicate measurement data to the upper completion section 100.

In embodiments in which power is generated or stored locally in thelower completion section, the controller cartridge 116 can include abattery or power supply.

As further depicted in FIGS. 1A and 2, the lower completion section 102includes a packer 120 (e.g., gravel pack packer) that when set sealsagainst casing 106. The packer 120 isolates an annulus region 124 underthe packer 120, where the annulus region 124 is defined between theoutside of the lower completion section 102 and the inner wall of thecasing 106 and the sand face 108.

A seal bore assembly 126 extends below the packer 120, where the sealbore assembly 126 is to sealably receive the upper completion section100. The seal bore assembly 126 is further connected to a circulationport assembly 128 that has a slidable sleeve 130 that is slidable tocover or uncover circulating ports of the circulating port assembly 128.During a gravel pack operation, the sleeve 130 can be moved to an openposition to allow gravel slurry to pass from the inner bore 132 of thelower completion section 102 to the annulus region 124 to perform gravelpacking of the annulus region 124. The gravel pack formed in the annulusregion 124 is part of the sand control assembly designed to filterparticulates.

In the example implementation of FIGS. 1A and 2, the lower completionsection 102 further includes a mechanical fluid loss control device,e.g., formation isolation valve 134, which can be implemented as a ballvalve. When closed, the ball valve isolates a lower part 136 of theinner bore 132 from the part of the inner bore 132 above the formationisolation valve 134. When open, the formation isolation valve 134 canprovide an open bore to allow flow of fluids as well as passage ofintervention tools. Although the lower completion section 102 depictedin the example of FIGS. 1A and 2 includes various components, it isnoted that in other implementations, some of these components can beomitted or replaced with other components.

As depicted in FIGS. 1A and 2, the sensor cable 112 is provided in theannulus region 124 outside the sand screen 110. By deploying the sensors114 of the sensor cable 112 outside the sand screen 110, well controlissues and fluid losses can be avoided by using the formation isolationvalve 134. Note that the formation isolation valve 134 can be closed forthe purpose of fluid loss control during installation of the two-stagecompletion system.

As depicted in FIGS. 1A and 3, the upper completion section 100 has astraddle seal assembly 140 for sealing engagement inside the seal boreassembly 126 (FIG. 2) of the lower completion section 102. As depictedin FIG. 1A, the outer diameter of the straddle seal assembly 140 of theupper completion section 100 is slightly smaller than the inner diameterof the seal bore assembly 126 of the lower completion section 102. Thisallows the upper completion section straddle seal assembly 140 tosealingly slide into the lower completion section seal bore assembly 126(which is depicted in FIG. 1A). In an alternate embodiment the straddleseal assembly can be replaced with a stinger that does not have to seal.

As depicted in FIG. 3, arranged on the outside of the upper completionsection straddle seal assembly 140 is a snap latch 142 that allows forengagement with the packer 120 of the lower completion section 102. Whenthe snap latch 142 is engaged in the packer 120, as depicted in FIG. 1A,the upper completion section 100 is securely engaged with the lowercompletion section 102. In other implementations, other engagementmechanisms can be employed instead of the snap latch 142.

Proximate to the lower portion of the upper completion section 100 (andmore specifically proximate to the lower portion of the straddle sealassembly 140) is a second inductive coupler portion 144 (e.g., a maleinductive coupler portion). When positioned next to each other, thesecond inductive coupler portion 144 and first inductive coupler portion118 (as depicted in FIG. 1A) form an inductive coupler that allows forinductively coupled communication of data and power between the upperand lower completion sections.

An electrical conductor 147 (or conductors) extends from the secondinductive coupler portion 144 to the control station 146, which includesa processor and a power and telemetry module (to supply power and tocommunicate signaling with the controller cartridge 116 in the lowercompletion section 102 through the inductive coupler). The controlstation 146 can also optionally include sensors, such as temperatureand/or pressure sensors.

The control station 146 is connected to an electric cable 148 (e.g., atwisted pair electric cable) that extends upwardly to a contractionjoint 150 (or length compensation joint). At the contraction joint 150,the electric cable 148 can be wound in a spiral fashion (to provide ahelically wound cable) until the electric cable 148 reaches an upperpacker 152 in the upper completion section 100. The upper packer 152 isa ported packer to allow the electric cable 148 to extend through thepacker 152 to above the ported packer 152. The electric cable 148 canextend from the upper packer 152 all the way to the earth surface (or toanother location in the well).

In another embodiment, the control station 146 can be omitted, and theelectrical cable 148 can run from the second inductive coupler portion144 (of the upper completion section 100) to a control station elsewherein the well or at the earth surface.

The contraction joint 150 is optional and can be omitted in otherimplementations. The upper completion section 100 also includes a tubing154, which can extend all the way to the earth surface. The uppercompletion section 100 is carried into the well on the tubing 154.

In operation, the lower completion section 102 is run in a first tripinto the well and is installed proximate to the open hole section of thewell. The packer 120 (FIG. 2) is then set, after which a gravel packingoperation can be performed. To perform the gravel packing operation, thecirculating port assembly 128 is actuated to an open position to openthe port(s) of the circulating port assembly 128. A gravel slurry isthen communicated into the well and through the open port(s) of thecirculating port assembly 128 into the annulus region 124. The annulusregion 124 is then filled with slurry until the annulus region 124 isgravel packed.

Next, in a second trip, the upper completion section 100 is run into thewell and attached to the lower completion section 102. Once the upperend lower completion sections are engaged, communication between thecontroller cartridge 116 and the control station 146 can be performedthrough the inductive coupler that includes the inductive couplerportions 118 and 144. The control station 146 can send commands to thecontroller cartridge 116 in the lower completion section 102, or thecontrol station 146 can receive measurement data collected by thesensors 114 from the controller cartridge 116.

FIG. 1B shows a slightly different view of the two-stage completionsystem depicted in FIG. 1A. In FIG. 1B, the sensor cable 112, controllercartridge 116, and control station 146 are depicted with slightlydifferent views. Functionally, the completion system of FIG. 1B issimilar to the completion system of FIG. 1A.

FIG. 1C is a schematic diagram of an example electrical chain betweenthe sensors 114 that are part of the lower completion section 102 and asurface controller 170 (provided at the earth surface). The sensors 114communicate over a bus 172 that is part of the sensor cable 112 to thecontroller cartridge 116. Communication between the controller cartridge116 and a control station interface 174 (part of control station 146)occurs through inductive coupler portions 118 and 144 (as discussedabove). A switch 176 can be provided in the controller cartridge 176 tocontrol whether or not communication is enabled through the inductivecoupler portions 118 and 144. The switch 176 is controllable by thecontrol station 146 or in response to commands sent from the surfacecontroller 170 through the control station 146. Note that, as discussedabove, the control station 146 can be omitted in some implementations,with the surface controller 170 being able to communicate with thecontroller cartridge 116 without the control station 146.

The control station 146 communicates power and signaling over electricalcable 148 to a communications bus interface 177. In one implementation,the communications bus interface 177 can be a ModBus interface, which isable to communicate over a ModBus communications link 178 with thesurface controller 170. The ModBus communications link 178 can be aserial link implemented with RS-422, RS-485, and/or RS-232, oralternatively, the ModBus communications link 178 can be a TCP/IP(Transmission Control Protocol/Internet Protocol). The ModBus protocolis a standard communications protocol in the oilfield industry andspecifications are broadly available, for example at www.modbus.org. Inalternative implementations, other types of communications links can beemployed.

In one implementation, the sensors 114 can be implemented as slavedevices that are responsive to requests from the control station 146.Alternatively, the sensors 114 can be able to initiate communicationswith the control station 146 or with the surface controller 170.

In one embodiment, communications through the inductive coupler portions118 and 144 is accomplished using frequency modulation of data signalsaround a particular frequency carrier. The frequency carrier hassufficient power to supply power to the controller cartridge 116 and thesensors 114. Alternatively, the controller cartridge 176 and sensors 114can be powered by a battery.

The sensors 114 can be scanned periodically, such as once everypredefined time interval. Alternatively, the sensors 114 are accessed inresponse to a specific request (such as from the control station 146 orsurface controller 170) to retrieve measurement data.

FIG. 1D illustrates yet another variant of the two-stage completionsystem. In the FIG. 1A embodiment, a single inductive coupler is used toprovide for both power and signal (data) communication. However,according to FIG. 1D, two inductive couplers are employed, an inductivecoupler 180 for power and an inductive coupler 182 for datacommunication.

FIG. 1E shows another embodiment that uses two inductive couplers 184and 186, where the first inductive coupler 184 is used for power anddata communication with a first sensor cable 188, and the secondinductive coupler 186 is used to provide power and data communicationwith a second sensor cable 190. The use of two inductive couplers andtwo corresponding sensor cables in the FIG. 1E embodiment provides forredundancy in case of failure of one of the sensor cables or one of theinductive couplers. The sensor cables 188 and 190 are generally parallelto each other. However, the sensors 192 of the sensor cable 188 areoffset along the longitudinal direction of the wellbore with respect tosensors 194 of the sensor cable 190. In other words, in the longitudinaldirection, each sensor 192 is positioned between two successive sensors194 (see dashed line 196 in FIG. 1E). Similarly, each sensor 194 ispositioned between two successive sensors 192 (see dashed line 198 inFIG. 1E). By providing longitudinal offsets of sensors 192 and 194, thesensors 192 and 194 are able to collect measurements at different depthsin the wellbore. In this manner, the effective density of sensors in theregion of interest is increased if both sensor cables 188 and 190 areoperational.

In another embodiment, the sensor cables 188 and 190 can be run inseries instead of in parallel as depicted in FIG. 1E. In yet anotherarrangement, instead of both cables 188 and 190 being sensor cables, oneof the cables can be a cable used to provide control, such as to controla flow control device (or alternatively, one of the cables can be acombination sensor and control cable).

In the embodiments discussed above, a sensor cable provides electricalwires that interconnect the multiple sensors in a collection or array ofsensors. In an alternative implementation, wires between sensors can beomitted. In this case, multiple inductive coupler portions can beprovided for corresponding sensors, with the upper completion sectionproviding corresponding inductive coupler portions to interact with theinductive coupler portions associated with respective sensors tocommunicate power and data with the sensors.

Moreover, even though reference has been made to communicating databetween the sensors and another component in the well, it is noted thatin alternative implementations, and in particular in implementationswhere sensors are provided with their own power sources downhole, thesensors can be provided with just enough micro-power that the sensorscan make measurements and store data over a relatively long period oftime (e.g., months). Later, an intervention tool can be lowered tocommunicate with the sensors to retrieve the collected measurement data.In one embodiment, the communication between the intervention tool wouldbe accomplished using inductive coupling, wherein one inductive couplerportion is permanently installed in the completion, and the matinginductive coupler portion is on the intervention tool. The interventiontool could also replenish (e.g., charge) the downhole power sources.

FIG. 4 illustrates a different embodiment of a two-stage completionsystem in which the positions of the inductive coupler portions and ofthe control station have been changed. The completion system includes anupper completion section 100A and a lower completion section 102A. Inthe FIG. 4 embodiment, the first inductive coupler portion 118 isprovided above a packer 204 (a ported packer) of the lower completionsection 102A. The first inductive coupler portion 118 can in turn beelectrically connected to the controller cartridge 116 (located belowthe packer 204), which is connected to a sensor cable 112A. The sensorcable 112A has a portion that passes through a port of the ported packer204 to allow communication between sensors 114 and the controllercartridge 116.

The upper completion section 100A has a lower section 208 that providesthe second inductive coupler portion 144 for communicating with thefirst inductive coupler portion 118 when the upper completion section100A is engaged with the lower completion section 102A.

In the embodiment of FIG. 4, the control station 146 is provided abovethe ported packer 152 (as compared to the position of the controlstation 146 below the ported packer 152 in FIGS. 1A and 3).

The remaining components depicted in FIG. 4 are the same as or similarto corresponding components in FIGS. 1A, 2, and 3 and thus are notfurther described.

FIG. 5 shows yet another variant of the two-stage completion system thatincludes an upper completion section 100B and a lower completion section102B. In this embodiment, a sensor cable 112B similar to the sensorcable 112 of FIG. 1A extends further up in the lower completion section102B to the controller cartridge 116 that is in turn connected to thefirst inductive coupler portion 118. The first inductive coupler portion118 is placed further up in the lower completion section 102B (ascompared to the lower completion section 102 of FIG. 1A) such that astraddle seal assembly 140B of the upper completion section 100B doesnot have to extend deeply into the lower completion section 102B. As aresult, when inserted into the lower completion section 102B, thestraddle seal assembly 140B of the upper completion section 100B doesnot extend past the circulating port assembly 128, such that thecirculating port 128 is not blocked when the upper completion section100B is engaged with the lower completion section 102B. In the FIG. 5embodiment, the inductive coupler portions 118 and 144 are positionedabove the circulating port assembly 128.

In the arrangement of FIG. 5, the control station 146 is also providedabove the ported packer 152 as in the FIG. 4 embodiment.

FIG. 6 shows a multi-stage completion system according to anotherembodiment that includes an upper completion section 100C and a lowercompletion section 102C that has multiple parts for multiple zones inthe well. As depicted in FIG. 6, three producing zones (or injectionzones) 302, 304, and 306 are depicted. The lower completion section 102Chas three sets of sensor cables 308, 310, and 312 that are similar inarrangement to the sensor cable 112 of FIG. 1. Each sensor cable 308,310, 312 has multiple sensors provided at discrete locations inrespective zones 302, 304, 306. In the arrangement of FIG. 6, the zones302, 304, and 306 are all lined with casing 314, unlike the open holesection depicted in FIG. 1. The casing 314 is perforated in each of thezones 302, 304, and 306 to enable communication between the well andreservoirs adjacent the well.

The lower completion section 102C includes a first lower packer 316 thatprovides isolation between zones 304 and 306, and a second lower packer318 that provides isolation between zones 304 and 302. The lowermostsensor cable 312 is electrically connected to a first set of inductivecoupler portions 318 and 320. The inductive coupler portion 318 isattached to a pipe section or screen that is attached to the first lowerpacker 316. On the other hand, the inductive coupler portion 320 isattached to another pipe section 324 or screen that extends upwardly toattach to another pipe section 326.

In the second zone 304, a second set of inductive coupler portions 328and 330 are provided, where the inductive coupler portion 328 isattached to pipe section 326. On the other hand, the inductive couplerportion 330 is attached to pipe section 332 that extends upwardly to theformation isolation valve 134 of the lower completion section 102C. Theremaining parts of the lower completion section 102C are similar to orthe same as the lower completion section 102B of FIG. 5. The uppercompletion section 100C that is engaged with the lower completionsection 102C is also similar to or the same as the upper completionsection 100B of FIG. 5.

In operation, the lower completion section 102C is installed indifferent trips, with the lowermost part of the lower completion section102C (that corresponds to the lowermost zone 306) installed first,followed by the second part of the lower completion zone 102C that isadjacent the second zone 304, followed by the part of the lowercompletion section 102C adjacent the zone 302.

Power and data communication between the controller cartridge 116 andthe sensors of the sensor cables 310 and 312 is performed through theinductive couplers corresponding to portions 328, 330, and 318, 320.

FIG. 7 shows a two-stage completion system according to yet anotherembodiment that includes a lower completion section 402 and an uppercompletion section 400. A casing 425 lines a portion of the well. In theFIG. 7 embodiment, an inductively coupled wet connect mechanism is notemployed, unlike the embodiments of FIGS. 1A-6. In FIG. 7, the lowercompletion section 402 includes a gravel pack packer 404 that isattached to a circulating port assembly 406. The lower completionsection 402 also includes a formation isolation valve 408 below thecirculating port assembly 406. A sand screen 410 is attached below theformation isolation valve 408 for sand control or control of otherparticulates. The lower completion section 402 is positioned proximateto an open hole zone 412 in which production (or injection) isperformed.

Note that in the FIG. 7 embodiment, the lower completion section 402does not include an inductive coupler portion. In the FIG. 7 embodiment,the upper completion section 400 has a stinger 414 that is made up of aslotted pipe having multiple slots to allow communication between theinner bore of the stinger 414 and the outside of the stinger 414. Thestinger 414 extends into the lower completion section 402 in theproximity of the open hole zone 412.

Within the stinger 414 is arranged a sensor cable 416 having multiplesensors 418 at discrete locations across the zone 412. The sensor cable416 extends upwardly in the stinger 414 until it exits the upper end ofthe stinger 414. The sensor cable 416 extends radially through a slottedpup joint 419 to a ported packer 420 of the upper completion section400. The slotted pup joint 419 has slots 422 to allow communicationbetween the inner bore 424 of a tubing 426 and the region 428 that isoutside the upper completion section 400 and underneath the packer 420.

In the upper completion section 400, a control station 430 is providedabove the packer 420. The sensor cable 416 extends through the portedpacker 420 to the control station 430. The control station 430 in turncommunicates over an electric cable 432 to an earth surface location orsome other location in the well.

Unlike the embodiments depicted in FIG. 1A-6, the sensors 418 of theFIG. 7 embodiment are arranged inside the sand control assembly (ratherthan outside the sand control assembly). However, use of the stinger 414allows for convenient placement of the sensors 418 across the sand faceadjacent the sand screen 410.

In operation, the lower completion section 402 of FIG. 7 is firstinstalled in the well adjacent the zone 412. Following gravel packing,the upper completion section 400 is run into the well, with the stinger414 inserted into the lower completion section 402 such that the sensors418 of the sensor cable 416 are positioned proximate to the zone 412 atvarious discrete locations. In some embodiment the lower completionsection may not require gravel packing; instead, the lower completionsection may include an expandable screen, cased and perforated hole,slotted liner, or open hole.

FIG. 8A shows yet another arrangement of a two-stage completion systemhaving an upper completion section 400A and lower completion section402A in which an inductively coupled wet connect mechanism is not used.A retrievable stinger 414A that is part of the upper completion section400A is inserted into the lower completion section 402A. The lowercompletion section 402A is similar to or identical to the lowercompletion section 402 of FIG. 7. However, the stinger 414A in FIG. 8Ahas a longitudinal groove on its outer surface in which a sensor cable416A is positioned. A cross-sectional view of a portion of the stinger414A with the sensor cable 416A is depicted in FIG. 9. As shown in FIG.9, a longitudinal groove (or dimple) 440 is provided in the outersurface of the stinger 414A such that the sensor cable 416A can bepositioned in the groove 440.

Referring again to FIG. 8A, the sensor cable 416A extends upwardly untilit reaches a stinger hanger 442 that rests in a stinger receptacle 444of a slotted pup joint 419A. The sensor cable 416A extends radiallythrough the stinger hanger 442 and the slotted pup joint 419A into aregion outside the outer surface of the upper completion section 400A.The sensor cable 416A extends through the ported packer 420 to thecontrol station 430.

Basically, the difference between the FIG. 8A embodiment and the FIG. 7embodiment is that the sensor cable 416A is arranged outside the stinger414A (rather than inside the stinger). Also, the stinger 414A isretrievable since it rests inside the stinger receptacle 444 on astinger hanger 442. (FIG. 7 shows a fixed stinger that is part of theupper completion section 400). An intervention tool can be run into thewell to engage the stinger hanger 442 of FIG. 8A to retrieve the stingerhanger 442 with the stinger 414A from the well. As depicted in FIG. 8A,a latching mechanism 446 is provided to engage the stinger hanger 442 tothe stinger receptacle 444. In one example implementation, the latchingmechanism 446 can be a snap latch mechanism.

Another difference between the upper completion section 400A of FIG. 8Aand the upper completion section 400 of FIG. 7 is that the uppercompletion section 400A has a slotted pipe section 448 extending belowthe stinger receptacle 444. The slotted pipe section 448 extends intothe lower completion section 402A, as depicted in FIG. 8A.

FIG. 8B illustrates another variant of the two-stage completion systemthat also employs a retrievable stinger 414B. The stinger 414B extendsfrom a stinger hanger 442B that rests in a stinger receptacle 444B. Thedifference between the FIG. 8B embodiment and the FIG. 8A embodiment isthat the stinger hanger 442B has a first inductive coupler portion 450(male inductive coupler portion) that is able to be inductively coupledto the second inductive coupler portion 452 (female inductive couplerportion) inside the stinger receptacle 444B. A sensor cable 416B (whichalso runs outside the stinger 414B but in a longitudinal groove) extendsupwardly and is connected to the first inductive coupler portion 450 inthe stinger hanger 442B. When the stinger hanger 442B is installedinside the stinger receptacle 444B, the first and second inductivecoupler portions 450 and 452 are positioned adjacent each other so thatelectrical signaling and power can be inductively coupled between theinductive coupler portions 450 and 452.

The second inductive coupler portion 452 is connected to an electriccable 454, which passes through the ported packer 420 to the controlstation 430 above the packer 420.

In operation, the lower completion section 402B is first run into thewell, followed by the upper completion section 400B in a separate trip.Then, the stinger 414B is run into the well, and installed in thestinger receptacle 444B of the upper completion section 400B.

FIG. 10 illustrates yet another embodiment of another completion systemthat provides sensors in a producing (or injection) zone. In theembodiment of FIG. 10, sensors 502 are provided outside a casing 504that lines the well. The sensors 502 are also part of a sensor cable506. The sensors 502 are provided at various discrete locations outsidethe casing 504. The sensor cable 506 runs upwardly to a first inductivecoupler portion 508 (female inductive coupler portion) through acontroller cartridge 507. The first inductive coupler portion 508interacts with a second inductive coupler portion 510 (male inductivecoupler portion) to communicate power and data. The first inductivecoupler portion 508 is located outside the casing 504, whereas thesecond inductive coupler portion 510 is located inside the casing 504.

Inside the casing 504, a packer 512 is set to isolate an annulus region514 that is above the packer 512 and between a tubing 516 and the casing504. The second inductive coupler portion 510 is electrically connectedto a control station 518 over an electric cable section 520. In turn,the control station 518 is connected to another electric cable 522 thatcan extend to the earth surface or elsewhere in the well.

In operation, the casing 504 is installed into the well with the sensorcable 506 and first inductive coupler portion 508 provided with thecasing 504 during installation. Subsequently, after the casing 504 hasbeen installed, the completion equipment inside the casing can beinstalled, including those depicted in FIG. 10. Prior to or afterinstallation of the components depicted in FIG. 10, a perforating gun(not shown) can be lowered into the well to the producing (or injection)zone 500. The perforating gun can then be activated to produceperforations 526 through the casing 504 and into the surroundingformation. Directional perforation can be performed to avoid damage tothe sensor cable 506 that is located outside the casing 504.

FIG. 11 illustrates yet another different arrangement of the completionsystem, which is similar to the completion system of FIG. 10 except thatthe completion system of FIG. 11 has multiple stages to correspond tomultiple different zones 602, 604, and 606. In the embodiment of FIG.11, a sensor cable 506A is also provided outside the casing 504, withthe sensor cable 506A having sensors 502 provided at various locationsin the different zones 602, 604, and 606. The sensor cable 506A extendsto the first inductive coupler portion 508 through the controllercartridge 507.

The completion system of FIG. 11 also includes the packer 512, thesecond inductive coupler portion 510 inside the casing 504, controlstation 518, and electric cable sections 520 and 522, as in the FIG. 10embodiment. The FIG. 11 embodiment differs from the FIG. 10 embodimentin that additional completion equipment is provided below the packer512. In FIG. 11, a gravel pack packer 608 is provided, with acirculating port assembly 610 provided below the gravel pack packer 608.A formation isolation valve 612 is also provided below the circulatingport assembly 610.

Further equipment below the formation isolation valve 612 include sandscreens 614 and isolation packers 616 and 618 to isolate the zones 602,604, and 606.

FIG. 12 illustrates another embodiment of a completion system that usesa stinger design and that does not use an inductively coupled wetconnect mechanism. The completion system includes an upper completionsection 700 and a lower completion section 702. In FIG. 12, a gravelpack packer 704 is set in a producing (or injection) zone, with a sandscreen 706 attached below the packer 704. The gravel pack packer 704 andscreen 706 are part of the lower completion section 702.

The upper completion section 700 includes a stinger 708 (which includesa perforated pipe). Within the inner bore of the stinger 708 arearranged various sensors 710 and 712. The sensors 710 and 712 areconnected by Y-connections to an electric cable 714. The electric cable714 runs through Y-connect bulkheads 716 and 720 and exits the upper endof the stinger 708. The electric cable 714 extends radially through aported sub 722 and then passes through a ported packer 724 of the uppercompletion section 700 to a control station 726. The control station 726in turn is connected by an electric cable 728 to the earth surface or toanother location in the well.

FIG. 13 shows a portion of a sensor cable 800 according to anembodiment, which can be any one of the sensor cables mentioned above.The sensor cable 800 includes outer housing sections 802 and 804, whichare sealably connected to a sensor housing structure 806 that houses asensor support 810 and a sensor 808. The sensor 808 is positioned in achamber 809 of the sensor support 810. The sensor support housing 806and the housing sections 802 and 804 of the sensor cable 800 can beformed of metal. The housing sections 802, 804 can be welded to sensorsupport housing 806 to provide a sealing engagement (to keep wellborefluids from entering the sensor cable 800). The sensor support 810 canalso be formed of a metal to act as a chassis. As an example, the metalused to form the sensor support 810 can be aluminum. Similarly, themetal used to form the housing sections 802, 804 and sensor supporthousing 806 can also be aluminum. If the sensor 808 is a temperaturesensor, then aluminum is a relatively good thermal coupler to allow foraccurate temperature measurement. However, in other implementations,other types of metal can be used. Also, non-metallic materials can alsobe used to implement elements 802, 804, 806, and 810.

As further depicted in FIG. 13, the sensor 808 includes a sensor chip812 (e.g., a sensor chip to measure temperature) and a communicationsinterface 814 (electrically connected to the sensor chip 812) to enablecommunication with electrical wires 816 and 818 that extend in thesensor cable 800. In one example implementation, the communicationsinterface 814 is an 12C interface. Alternatively, other types ofcommunications interfaces can be used with the sensor 808. The sensorchip 812 and interface 814 can be mounted on a circuit board 811 in oneimplementation.

The portion depicted in FIG. 13 is repeated along the length of thesensor cable 800 to provide multiple sensors 808 along the sensor cable800 at various discrete locations. In accordance with some embodiments,the sensor cable 800 is implemented with bi-directional twisted pairwires, which have relatively high immunity to noise. Signals on twistedpair wires are represented by voltage differences between two wires. Thesuccessive housing sections 802, 804 and sensor housing structures 806are collectively referred to as the “outer liner” of the sensor cable800.

A benefit of using welding in the sensor cable is that O-ring ordiscrete metal seals can be avoided. However, in other implementations,O-ring or metal seals can be used. In an alternative implementation,instead of using welding to weld the housing sections 802, 804 with thesensor support housing 806, other forms of sealing engagement orattachment can be provided between the housing sections 802, 804, andsensor support housing 806.

FIG. 14 illustrates a sensor cable 800A according to a differentembodiment. In this embodiment, housing sections 802, 804 of the sensorcable 800A are sealably connected to a sensor support housing 806A thathas an outer diameter wider than the outer diameter of the housingsections 802, 804. In other words, the sensor support housing 806Aprotrudes radially outwardly with respect to the housing sections 802,804. As with the sensor cable 800 of FIG. 13, the housing sections 802,804 can be welded to the sensor support housing 806A to provide sealingengagement. Alternatively, other forms of sealing engagement orattachment can be employed. The enlarged diameter or width of the sensorsupport housing 806A allows for a cavity 824 to be defined in the sensorsupport housing 806A. The cavity 824 can be used to receive a pressureand temperature sensor element 826, which can be used to detect bothpressure and temperature (or just one of pressure and temperature) orany other type of sensors. An outer surface 828 of the sensor element826 is exposed to the external environment outside the sensor cable800A. The sensor element 826 is sealably attached to the sensor supporthousing 806A by connections 830, which can be welded connections orother types of sealing connections.

Wires 832 connect the sensor element 826 to sensor 808A contained in thesensor support 810 inside the sensor support housing 806A. The wires 832connect the sensor element 826 to the sensor chip 812 of the sensor808A, which sensor chip 812 is able to detect pressure and temperaturebased on signals from the sensor element 826.

FIG. 15 shows a sensor cable 800 that is deployed on a spool 840. Asdepicted in FIG. 15, the sensor cable 800 includes the controllercartridge 116 and a sensor 114. Additional sensors 114 that are part ofthe sensor cable 800 are wound onto the spool 840. To deploy the sensorcable 800, the sensor cable 800 is unwound until a desired length (andnumber of sensors 114) has been unwound, and the sensor cable 800 can becut and attached to a completion system.

FIG. 16 shows an alternative embodiment of a sensor cable 900, which ismade up of a control line 902 (which can be formed of a metal such assteel, for example). Note that the control line 902 is a continuouscontrol line that includes multiple sensors. The control line 902 has aninner bore 904 in which sensors 906 are provided, where the sensors 906are interconnected by electrical wires 908. In accordance with someembodiments, the inner bore 904 of the control line 902 is filled with anon-electrically conductive liquid to provide efficient heat transferbetween the outside of the control line 902 and the sensors 906. Thenon-electrically conductive liquid (or other fluid) in the inner bore904 is thermally conductive to provide the heat transfer. Also, thefluid in the control line 902 allows for averaging of temperature over acertain length of the control line 902, due to the thermally conductivecharacteristics of the fluid.

In accordance with some embodiments, the sensors 906 can be implementedwith resistance temperature detectors (RTDs). RTDs are thin film devicesthat measure temperature based on correlation between electricalresistance of electrically-conductive materials and changingtemperature. In many cases, RTDs are formed using platinum due toplatinum's linear resistance-temperature relationship. However, RTDsformed of other materials can also be used. Precision RTDs are widelyavailable within the industry, for example, from Heraeus SensorTechnology, Reinhard-Heraeus-Ring 23, D-63801 Kleinostheim, Germany.

The use of inductive coupling according to some embodiments enables asignificant variety of sensing techniques, not just temperaturemeasurements. Pressure, flow rate, fluid density, reservoir resistivity,oil/gas/water ratio, viscosity, carbon/oxygen ratio, acousticparameters, chemical sensing (such as for scale, wax, asphaltenes,deposition, pH sensing, salinity sensing), and so forth can all receivepower and/or data communication through inductive coupling. It isdesirable that sensors be of small size and have relatively low powerconsumption. Such sensors have recently become available in theindustry, such as those described in WO 02/077613. Note that the sensorsmay be directly measuring a property of the reservoir, or the reservoirfluid, or they may be measuring such properties through an indirectmechanism. For example, in the case that geophones or acoustic sensorsare located along the sand face and where such sensors measure acousticenergy generated in the formation, that energy may come from the releaseof stress caused by the cracking of rock formation in a hydraulicfracturing of a nearby well. This information in turn is used todetermine mechanical properties of the reservoir, such as principlestress directions, as has been described, for example, in U.S.Publication No. 2003/0205376.

The uppermost sensor 906 depicted in FIG. 16 is connected by wires 910to a splice structure 912, which interconnects the wires 910 to wires914 inside a control line 915 that leads to a controller cartridge (notshown in FIG. 16). Note that the splice structure 912 is provided toisolate the fluids in the control line bore 904 from a chamber 916 inthe control line 915.

FIG. 17 illustrates a different arrangement of a sensor cable 900A. Thesensor cable 900A also includes the control line 902 that defines theinner bore 904 containing a non-electrically conductive fluid. However,the difference between the sensor cable 900A of FIG. 17 and the sensorcable 900 of FIG. 16 is the use of modified sensors 906A in FIG. 17. Thesensors 906A include an RTD wire filament 920 (which has a resistancethat varies with temperature). The filament 920 is connected to anelectronic chip 922 for detecting the resistance of the RTD wirefilament 920 to enable temperature detection.

FIG. 18 illustrates yet another arrangement of a sensor cable 900B. Inthis embodiment, the control line 902 does not contain a liquid (rather,the inner bore 904 of the control line 902 contains air or some othergas). The sensor cable 900B includes sensors 906B have an encapsulatingstructure 930 to contain a non-electrically conductive liquid 932 inwhich the RTD filament wire 920 and electronic chip 922 are provided.

FIG. 19 shows a longitudinal cross-sectional view of another embodimentof a completion system that includes a shunt tube 1002 for carryinggravel slurry for gravel packing operations. The shunt tube 1002 extendsfrom an earth surface location to the zones of interest. Two zones 1004and 1006 are depicted in FIG. 19, with packers 1008 and 1010 used forzonal isolation.

In the first zone 1004, a screen assembly 1112 is provided around aperforated base pipe 1114. As depicted, fluid is allowed to flow fromthe reservoir in zone 1004 through the screen assembly 1112 and throughperforations of the perforated pipe 1114 into an inner bore 1116 of thecompletion system depicted in FIG. 19. Once the fluid enters the innerbore 1116, fluid flows in the direction indicated by arrows 1118.

The perforated base pipe 1114 at its lower end is connected to a blankpipe 1120. The lower end of the blank pipe 1120 is connected to anotherperforated base pipe 1122 that is positioned in the second zone 1006. Ascreen assembly 1124 is provided around the perforated base pipe 1122 toallow fluid flow from the reservoir adjacent zone 1006 to flow fluidinto the inner bore 1116 of the completion system through the screenassembly 1124 and the perforated base pipe 1122.

The perforated base pipes 1114, 1122, and the blank pipe 1120 make up aproduction conduit that contains the inner bore 1116. The shunt tube1002 is provided in an annular region between the outside of thisproduction conduit and a wall 1126 of the wellbore. In FIG. 19, the wall1126 is a sand face. Alternatively, the wall 1126 can be a casing orliner.

As further depicted in FIG. 19, sensors 1128, 1130, and 1132 areattached to the shunt tube 1002. The sensor 1128 is provided in the zone1004 and the sensor 1132 is provided in the zone 1006. The sensors 1128and 1132 are placed in radial flow paths of the respective zones 1004and 1006. On the other hand, the sensor 1130 is positioned betweenpackers 1008 and 1110, which is in a non-flowing area of the wellbore(no fluid flow in the radial direction or longitudinal direction in thespace 1134 that is defined between the two packers 1008 and 1110 andbetween the blank pipe 1120 and the inner wall 1126 of the wellbore).

The sensors 1128, 1130, and 1132 are sensors on a sensor cable. Across-sectional view of the shunt tube 1002 and a sensor cable 1136 isdepicted in FIG. 20. The shunt tube 1002 has an inner bore 1138 in whichgravel slurry is flowed when performing gravel packing operations. In agravel packing operation, gravel slurry is pumped down the inner bore1138 of the shunt tube 1002 to annular regions in the wellbore that areto be gravel packed. Attached to the shunt tube 1002 is a sensor holderclip 1140 (that is generally C-shaped in the example implementation).The sensor cable 1136 is held in place by the sensor holder clip 1140.The sensor holder clip 1140 is attached to the shunt tube 1002 by anyone of various mechanisms, such as by welding or by some other type ofconnection. In an alternate embodiment, the shunt tubes can be omittedand a screen without shunt tube is used. The gravel is pumped in theannular cavity between the screen outer surface and wall of the well. Acable protector is attached to a screen base pipe between successivesections of the screen (or slotted or perforated pipe) for protectingthe sensor and cable. In another embodiment, the sensor cable andsensors are secured to contact a base pipe such that the base pipeprovides both an electrical ground for the sensor cable and sensors, andacts as a heat sink to allow dissipation of heat from the sensor cableand sensors to the base pipe.

FIG. 21 shows an example completion system for use with a multilateralwell. In the example of FIG. 21, the multilateral well includes a mainwellbore section 1502, a lateral branch 1504, and a section 1505 of themain wellbore 1502 that extends below the lateral branch junctionbetween the main wellbore 1502 and the lateral branch 1504.

As depicted in FIG. 21, the main wellbore 1502 is lined with casing1506, with a window 1508 formed in the casing 1506 to enable a lateralcompletion 1510 to pass into the lateral branch 1504.

An upper completion section 1512 is provided above the lateral branchjunction. The upper completion section 1512 includes a production packer1514. Attached above the production packer 1514 is a production tubing1516, to which a control station 1518 is attached. The control station1518 is connected by an electric cable 1520 that passes through theproduction packer 1514 to an inductive coupler 1522 below the productionpacker 1514.

The completion in the main wellbore and the lateral is very similar tothe FIG. 1A embodiment. In a variant of the FIG. 1A embodiment, flowcontrol devices that are remotely controlled are provided. The power andcommunication from the main bore to lateral is accomplished though aninductive coupler 1522.

In turn, the electric cable 1520 (which is part of a lower completionsection 1526) further passes through a lower packer 1532. The electriccable 1520 connects the inductive coupler 1522 to control devices (e.g.,flow control valves) 1528 and sensors 1530. The lower completion section1526 also includes a screen assembly 1538 to perform sand control. Thesensors 1530 are provided proximate to the sand control assembly 1538.The lower completion may not include screen in some embodiments.

Depending on the multilateral junction construction and type aninductive coupler is run with the junction. A cable is run from junctioninductive coupler to flow control valves and sensors in the junctioncompletion similar to the FIG. 1A embodiment. The cable 1534 frominductive coupler 1522 connects to the flow control valve and sensor1536 in the completion in the lateral section 1504.

As part of the lower completion section 1526, another inductive coupler1531 is provided to allow communication between the electric cable 1520and an electric cable of the main bore completion that extends into themain bore section 1505 to flow control devices and/or sensors 1528 and1530 in the main bore section 1505.

FIG. 22 shows another embodiment of a two-stage completion system thatis a variant of the FIG. 1A embodiment. In the FIG. 22 embodiment, flowcontrol devices 1202 (or other types of control devices that areremotely controllable) are provided with the sand control assembly 110.The flow control devices (or other remotely-controllable devices) areconnected by respective electrical connections 1204 (such as in the formof electrical wires) to the sensor cable 112.

With this implementation, the sensor cable 112 not only is able toprovide communication with sensors 114, but also is able to enable awell operator to control flow control devices (or otherremotely-controllable devices) located proximate to a sand controlassembly from a remote location, such as at the earth surface.

The types of flow control devices 1202 that can be used includehydraulic flow control valves (which are powered by using a hydraulicpump or atmospheric chamber that is controlled with power and signalfrom the earth surface through the control station 146); electric flowcontrol valves (which are powered by power and signaling from the earthsurface through the control station 146); electro-hydraulic valves(which are powered by power and signaling from the earth surface throughthe control station 146 and the inductive coupler); and memory-shapedalloy valves (which are powered by power and signaling from the earthsurface through the control station and inductive coupler).

With electric flow control valves, a storage capacitance (in the form ofa capacitor) or any other power storage device can be employed to storea charge that can be used for high actuation power requirements of theelectric flow control valves. The capacitor can be trickle charged whennot in use.

For electro-hydraulic valves, which employ pistons to control the amountof flow through the electro-hydraulic valves, signaling circuitry andsolenoids can control the amount of fluid distribution within thepistons of the valves to allow for a large number of choke positions forfluid flow control.

A memory-shaped alloy valve relies on changing the shape of a member ofthe valve to cause the valve setting to change. Signaling is applied tochange the shape of such element.

FIG. 23 depicts yet another arrangement of a two-stage completion systemhaving an upper completion section 1306 and a lower completion section1322. The upper completion section 1306 includes flow control valves1302 and 1304, which are provided to control radial flow betweenrespective zones 1308 (upper zone) and 1310 (lower zone) and an innerbore 1312 of the completion system. The flow control valve 1302 is an“upper” flow control value, and the flow control valve 1304 is a “lower”flow control valve. Cable 1338 from surface is electrically connected toflow control valves 1302 and 1304 through electrical conductors (notshown).

The upper completion section 1306 further includes a production packer1314. A pipe section 1316 extends below the production packer 1314. Amale inductive coupler portion 1318 is provided at a lower end of thepipe section 1316. The male inductive coupler portion 1318 interacts oraxially aligns with a female inductive coupler portion 1320 that is partof the lower completion section 1322. The inductive coupler portions1318 and 1320 together form an inductive coupler that provides aninductively coupled wet connect mechanism.

The upper completion section 1306 further includes a housing section1324 to which the flow control valve 1302 is attached. The housingsection 1324 is sealably engaged to a gravel packer 1326 that is part ofthe lower completion section 1322. At the lower end of the housingsection 1324 is another male inductive coupler portion 1328, whichinteracts with another female inductive coupler portion 1330 that ispart of the lower completion section 1322. Together, the inductivecoupler portions 1328 and 1330 form an inductive coupler.

Below the inductive coupler portion 1328 is the lower flow control valve1304 that is attached to a housing section 1332 of the upper completionsection 1306 proximate to the lower zone 1310.

The upper completion section 1306 further includes a tubing 1334 abovethe production packer 1314. Also, attached to the tubing 1334 is acontrol station 1336 that is connected to an electric cable 1338. Theelectric cable 1338 extends downwardly through the production packer1314 to electrically connect electrical conductors extending through thepipe section 1316 to the inductive coupler portion 1318, and to electricconductors extending through the housing section 1324 to the lowerinductive coupler portion 1328. The flow control valves 1302 and 1304 inone embodiment can be hydraulically actuated. A hydraulic control lineis run from surface to a valve for operating the valve. In yet anotherembodiment, the flow control valve can be electrically operated,hydroelectrically operated, or operated by other means.

In the lower completion section 1322, the upper inductive couplerportion 1320 is coupled through a controller cartridge (not shown) to anupper sensor cable 1340 having sensors 1342 for measuringcharacteristics associated with the upper zone 1308. Similarly, thelower inductive coupler portion 1330 is coupled through a controllercartridge (not shown) to a lower sensor cable 1344 that has sensors 1346for measuring characteristics associated with the lower zone 1310.

At its lower end, the lower completion section 1322 has a packer 1348.The lower completion section 1322 also has a gravel pack packer 1350 atits upper end.

In the FIG. 23 embodiment, two inductive couplers are used for thesensor arrays 1342 and 1346, respectively. The cable 1338 is run toinductive coupler 1318 and also to flow control valve 1302 and 1304. Inan alternative embodiment, as depicted in FIG. 24, a single inductivecoupler is used that includes inductive coupler portions 1318 and 1320.In the FIG. 24 embodiment, a single sensor cable 1352 is provided in anannulus region between the casing 1301 and sand control assemblies 1343,1345. The sensor cable 1352 extends through the isolation packer 1326 toprovide sensors 1342 in upper zone 1308, and sensors 1346 in lower zone1310.

In the embodiments of FIGS. 23 and 24, flow control valves are providedas part of the upper completion section. In FIG. 25, on the other hand,the flow control valves 1302 and 1304 are provided as part of a lowercompletion section 1360. In the FIG. 25 embodiment, the upper completionsection 1362 has a male inductive coupler portion 1364 that is able tocommunicate with a female inductive coupler portion 1366 that isprovided as part of the lower completion section 1360. The lowercompletion section 1360 is attached by a screen hanger packer 1368 tocasing 1301.

The inductive coupler portions 1364 and 1366 form an inductive coupler.The inductive coupler portion 1366 of the lower completion section 1362is coupled through a controller cartridge (not shown) to a sensor cable1368 that extends through an isolation packer 1370 that is also part ofthe lower completion section 1362. The isolation packer 1370 isolatesthe upper zone 1308 from the lower zone 1310.

The sensor cable 1368 is connected by cable segments 1372 and 1374 torespective flow control valves 1302 and 1304.

FIG. 26 illustrates yet another embodiment of a completion system inwhich an inductive coupler is not used. The completion system of FIG. 26includes an upper completion section 1381 and a lower completion section1380. In this embodiment, sensors 1382 (for the upper zone 1308) andsensors 1384 (for the upper zone 1310) are part of the upper completionsection 1381. The lower completion section 1380 does not include sensorsor inductive couplers. The lower completion section 1380 includes agravel pack packer 1386 connected to a sand control assembly 1388, whichin turn is connected to an isolation packer 1390. The isolation packer1390 is in turn connected to another sand control assembly 1392 for thelower zone 1310.

The sensors 1382, 1384 and flow control valves 1302, 1304 that are partof the upper completion section 1381 are connected by electricconductors (not shown) that extend to an electric cable 1394. Theelectric cable 1394 extends through a production packer 1396 of theupper completion section 1381 to a control station 1398. Control station1398 is attached to tubing 1399.

FIG. 27 shows yet another embodiment of a completion system having anupper completion section 1400A, an intermediate completion 1400B and alower completion section 1402. The well of FIG. 27 is lined with casing1401. In some embodiment the reservoir section may not be lined withcasing but may be an open hole, an open hole with expandable screen, anopen hole with stand alone screen, an open hole with slotted liner, anopen hole gravel pack, or a frac-pack or resin consolidated open hole.The completion system of FIG. 27 includes formation isolation valves,including formation isolation valves 1404 and 1406 that are part of thelower completion section 1402. The lower completion section can be asingle trip multi-zone or multiple trip multi-zone completion. Anotherformation isolation valve is an annular formation isolation valve 1408to provide annular fluid loss control—the annular formation isolationvalve 1408 is part of the intermediate completion section 1400B toprovide formation isolation for the upper zone 1416 after the upperformation isolation valve 1404 is opened to insert the inner flow string1409 inside the lower completion section 1402 In some embodiments, aformation isolation valve similar to 1404 can be run below the annularformation isolation valve 1408 as part of the intermediate completion1400B to isolate the lower zone after the lower formation valve 1406 isopened to insert the inner flow string 1409 inside the lower zone 1420.

A sensor cable 1410 is provided as part of the intermediate completionsection 1400B, and runs to a male inductive coupler portion 1452 that isalso part of the upper completion section 1400A. A length compensationjoint 1411 is provided between the production packer 1436 and the maleinductive coupler 1452. The length compensation joint 1411 allows theupper completion to land out in the profile at the female inductivecoupler portion 1412, with the production tubing or upper completionattached to the tubing hanger at the wellhead (at the top of the well).The length compensation joint 1411 includes a coiled cable to allowchange in length of the cable with change in length of the compensationjoint. The cable 1438 is joined to the coiled cable and the lower end ofthe coil is connected to the male inductive coupler 1452. The sensorcable 1410 is electrically connected to the female inductive couplerportion 1412 and runs outside of the inner flow string 1409. The sensorcable 1410 provides sensors 1414 and 1418. The cable 1410 between twozones 1416 and 1420 is fed through a seal assembly 1429. The sealassembly 1429 seals inside the packer bore or other polished bore ofpacker 1428.

The intermediate completion 1400B includes the female inductive couplerportion 1412, annular formation isolation valve 1408, inner flow string1409, sensor cable 1414, and seal assembly 1429 with feed through is runon a separate trip. The inner flow string 1409, sensor cable 1414, andseal assembly 1429 are run inside (in an inner bore) the lowercompletion section 1402. The sensor cable 1414 provides sensors 1414 forthe upper zone 1416, and sensors 1418 for the lower zone 1420.

Other components that are part of the lower completion section 1402include a gravel pack packer 1422, a circulating port assembly 1424, asand control assembly 1426, and isolation packer 1428. The circulatingport assembly 1424, formation isolation valve 1404, and sand controlassembly 1426 are provided proximate to the upper zone 1416.

The lower completion section 1402 also includes a circulating portassembly 1430 and a sand control assembly 1432, where the circulatingport assembly 1430, formation isolation valve 1406, and sand controlassembly 1432 are proximate to the lower zone 1420.

The upper completion section 1400A further includes a tubing 1434 thatis attached to a packer 1436, which in turn is connected to a flowcontrol assembly 1438 that has an upper flow control valve 1440 and alower flow control valve 1442. The lower flow control valve 1442controls fluid flow that extends through a first flow conduit 1444,whereas the upper flow control valve 1440 controls flow that extendsthrough another flow conduit 1446. The flow conduit 1446 is in anannular flow path around the first flow conduit 1444. The flow conduit1444 (which can include an inner bore of a pipe) receives flow from thelower zone 1420, whereas the flow conduit 1446 receives fluid flow fromthe upper zone 1416.

The upper completion section 1400A also includes a control station 1448that is connected by an electric cable 1450 to the earth surface. Also,the control station 1448 is connected by electric conductors (not shown)to a male inductive coupler portion 1452, where the male inductivecoupler portion 1452 and the female inductive coupler portion 1412 makeup an inductive coupler.

FIG. 28 shows yet another embodiment of a completion system that is avariant of the FIG. 27 embodiment that does not require an intermediatecompletion (1400B in FIG. 27) to deploy the annular formation isolationvalve. The completion system of FIG. 28 includes an upper completionsection 1460 and a lower completion section 1462. An annular formationisolation valve 1408A incorporated into a sand control assembly 1464that is part of the lower completion section 1462.

A sensor cable 1466 extends from a female inductive coupler portion1468. The female inductive coupler portion 1468 (which is part of thelower completion section 1462) interacts with a male inductive couplerportion 1470 to form an inductive coupler. The male inductive couplerportion 1470 is part of the inner flow string 1409 that extends from theupper completion section 1460 into the lower completion section 1462. Anelectric cable 1474 extends from the male inductive coupler portion 1470to a control station 1476.

The upper completion section 1460 also includes the flow controlassembly 1438 similar to that depicted in FIG. 27.

In various embodiments discussed above, various multi stage completionsystems that include an upper completion section and a lower completionsection and/or intermediate completion section have been discussed. Insome scenarios, it may not be appropriate to provide an upper completionsection after a lower completion section has been installed. This may bebecause of the well is suspended after the lower completion is done. Insome cases, wells in the field are batch drilled and lower completionsare batch completed and then suspended and then at later date uppercompletions are batch completed. Also in some cases it may be desirableto establish a thermal gradient across the formation for the purpose ofcomparison with changing temperature or other formation parametersbefore disturbing the formation to aid in analysis. In such cases, itmay be desirable to take advantage of sensors that have already beendeployed with the lower completion section of the two-stage completionsystem. To be able to communicate with the sensors that are part of thelower completion section, an intervention tool having a male inductivecoupler portion can be lowered into the well so that the male inductivecoupler portion can be placed proximate to a corresponding femaleinductive coupler portion that is part of the lower completion section.The inductive coupler portion of the intervention tool interacts withthe inductive coupler portion of the lower completion section to form aninductive coupler that allows measurement data to be received from thesensors that are part of the lower completion section.

The measurement data can be received in real-time through the use of acommunication system from the intervention tool to the surface, or thedata can be stored in memory in the intervention tool and downloaded ata later time. In the case that a real-time communication is used, thiscould be via a wireline cable, mud-pulse telemetry, fiber-optictelemetry, wireless electromagnetic telemetry or via other telemetryprocedures known in the industry. The intervention tool can be loweredon a cable, jointed pipe, or coiled tubing. The measurement data can betransmitted during an intervention process to help monitor the state ofthat intervention.

FIG. 29 shows an example of such an arrangement. The lower completionsection depicted in FIG. 29 is the same lower completion section of FIG.2 discussed above. In the FIG. 29 arrangement, the upper completionsection has not yet been deployed. Instead, an intervention tool 1500 islowered on a carrier line 1502 into the well. The intervention tool 1500has an inductive coupler portion 1504 that is capable of interactingwith the inductive coupler portion 118 in the lower completion section102.

The carrier line 1502 can include an electric cable or a fiber opticcable to allow communication of data received through the inductivecoupler portions 118, 1504 to an earth surface location.

Alternatively, the intervention tool 1500 can include a storage deviceto store measurement data collected from the sensors 114 in the lowercompletion section 102. When the intervention tool 1500 is laterretrieved to the earth surface, the data stored in the storage devicecan be downloaded. In this latter configuration, the invention tool 1500can be lowered on a slickline, with the intervention tool including abattery or other power source to provide energy to enable communicationthrough the inductive coupler portions 118, 1504 with the sensors 114.

A similar intervention-based system can also be used for coiled tubingoperation. During the coiled tubing operation, it may be beneficial tocollect sand face data to help decide what fluids are being pumped intothe wellbore through the coiled tubing and at what rate. Measurementdata collected by the sensors can be communicated in real time back tothe surface by the intervention tool 1500.

In another implementation, the intervention tool 1500 can be run on adrill pipe. With a drill pipe, however, it is difficult to provide anelectric cable along the drill pipe due to joints of the pipe. Toaddress this, electric wires can be embedded within the drill pipe withcoupling devices at each joint provided to achieve a wired drill pipe.Such a wired drill pipe is able to transmit data and also allow forfluid transmission through the pipe.

The intervention-based system can also be used to perform drillstemtesting, with measurement data collected by the sensors 114 transmittedto the earth surface during the test to allow the well operator toanalyze results of the drillstem testing.

The lower completion section 102 can also include components that can bemanipulated by the intervention tool 1500, such as sliding sleeves thatcan be opened or closed, packers that can be set or unset, and so forth.By monitoring the measurement data collected by the sensors 114, a welloperator can be provided with real-time indication of the success of theintervention (e.g., sliding sleeve closed or open, packer set or unset,etc.).

In an alternative implementation, the lower completion section 102 caninclude multiple female inductive coupler portions. The single maleinductive coupler portion (e.g., 1504 in FIG. 29) can then be loweredinto the well to allow communication with whichever female inductivecoupler portion the male inductive coupler portion is positionedproximate to.

Note that the intervention tool 1500 depicted in FIG. 29 can also beused in a multilateral well that has multiple lateral braches. Forexample, if one of the lateral branches is producing water, theintervention tool 1500 can be used to enter the lateral branch with coiltubing to allow pumping of a flow inhibitor into the lateral branch tostop the water production. Note that surface measurements would not beable to indicate which lateral branch was producing water; only downholemeasurements can perform this detection.

Each of the lateral branches of the multilateral well can be fitted witha measurement array and an inductive coupler portion. In such anarrangement, there would be no need for a permanent power source in eachlateral branch. During intervention, the intervention tool can access aparticular lateral branch to collect data for that lateral branch, whichwould provide information about the flow properties of the lateralbranch. In some implementations, the sensors or the controller cartridgeassociated with the sensors in each lateral branch can be provided withan identifying tag or other identifier, so that the intervention toolwill be able to determine which lateral branch the intervention tool hasentered.

Note also that tags within the measurement system can change propertiesbased on results of the measurement system (e.g., to change a signal ifthe measurement system detects significant water production). Theintervention tool can be programmed to detect a particular tag, and toenter a lateral branch associated with such particular tag. This wouldsimplify the task of knowing which lateral branch to enter foraddressing a particular issue.

While the invention has been disclosed with respect to a limited numberof embodiments, those skilled in the art, having the benefit of thisdisclosure, will appreciate numerous modifications and variationstherefrom. It is intended that the appended claims cover suchmodifications and variations as fall within the true spirit and scope ofthe invention.

What is claimed is:
 1. A sensor assembly for deployment into a well,comprising: a sand screen configured to prevent passage of particulatematerial into a completion section; a sensor cable comprising: an outerliner; a plurality of spaced apart sensors inside the outer liner,wherein the sensors are spaced apart longitudinally along a length ofthe cable; and wires inside the outer liner to interconnect theplurality of sensors; wherein the sensor cable is deployed proximate tothe sand screen in the well.
 2. The sensor cable of claim 1, wherein theouter liner includes a continuous control line.
 3. The sensor cable ofclaim 1, wherein the liner is made up of housing sections and sensorhousing structures sealably connected to the housing sections, whereinthe sensors are contained in respective sensor housing structures. 4.The sensor cable of claim 3, wherein the housing sections are welded tothe sensor housing structures.
 5. The sensor cable of claim 1, whereineach sensor includes a sensor chip and a communications interfaceconnected to at least one of the wires.
 6. The sensor cable of claim 5,wherein each sensor further includes a sensing element for sensing anenvironment outside the sensor cable, wherein the sensing element iselectrically connected to the sensor chip.
 7. The sensor cable of claim1, further comprising a controller cartridge that is part of the liner,the controller cartridge having a processor.
 8. A sensor cable fordeployment in a well, comprising: a control line defining an innerchamber containing a non electrically conductive liquid; and pluralsensors in the liquid.
 9. The sensor cable of claim 8, wherein thesensors include resistance temperature detectors.
 10. The sensor cableof claim 9, wherein the liquid is thermally conductive.
 11. The sensorcable of claim 8, wherein each resistance temperature detector includesan electronic chip and a resistance temperature detector filamentelectrically connected to the electronic chip.
 12. The sensor cable ofclaim 8, further comprising individual encapsulating structures in theinner chamber, the sensors located in respective encapsulatingstructures, the encapsulating structures containing the liquid, andwherein the inner chamber outside the encapsulating structures is filledwith gas.
 13. An apparatus comprising: a spool; and a sensor cable woundon the spool and deployable from the spool by rotating the spool,wherein the sensor cable includes multiple sensors located at aplurality of discrete locations along the sensor cable, and wherein thesensor cable has electrical wires interconnecting the sensors.
 14. Thesensor cable of claim 1 wherein the completion section defines anannulus region between the completion section and an interior surface ofthe well, wherein the sensor cable is positioned between within theannulus region spaced apart from the completion section and the interiorsurface of the well.